Multilevel vertical conveyor platform guides

ABSTRACT

A multilevel vertical conveyor system for transporting uncontained case units to and from a multilevel storage structure having an array of vertically stacked storage levels is provided and includes a frame having platform guide members, a drive member connected to the frame, and support platforms coupled to the drive member. The drive member is configured to move the support platforms relative to the frame in a substantially continuous vertical loop, each of the support platforms being configured to support multiple uncontained case units where each of the multiple uncontained case units is disposed at a respective predetermined area of a respective support platform, the support platforms have support members that are guided by guide members substantially throughout a path of the substantially continuous vertical loop, where the support members are guided in three point contact by the guide members substantially throughout the path.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.13/327,088 filed on Dec. 15, 2011 and is non-provisional of and claimsthe benefit of U.S. provisional patent application Ser. No. 61/423,298filed on Dec. 15, 2010, the disclosures of which are incorporated byreference herein in their entireties.

BACKGROUND

1. Field

The embodiments generally relate to material handling systems and, moreparticularly, to automated storage and retrieval systems.

2. Brief Description of Related Developments

Warehouses for storing case units may generally comprise a series ofstorage racks that are accessible by transport devices such as, forexample, fork lifts, carts and elevators that are movable within aislesbetween or along the storage racks or by other lifting and transportingdevices. These transport devices may be automated or manually driven.Generally, where the case units are stored in multilevel racks, caseunits are placed on the different levels of the racks with a liftingdevice on the transport device. Where the case units are stored in rackslocated on different floors or levels of the storage structure the caseunits are generally transported between the floors while disposed on thetransport devices where the transport devices travel up and down rampsspanning between the floors. In other examples the transport device withthe case units disposed thereon are raised and lowered between thefloors with an elevator. Generally, the case units carried by thetransport devices and stored on the storage racks are contained incarriers, for example storage containers such as trays, totes orshipping cases, or on pallets. Generally, incoming pallets to thewarehouse (such as from manufacturers) contain shipping containers (e.g.cases) of the same type of goods. Outgoing pallets leaving thewarehouse, for example, to retailers have increasingly been made of whatmay be referred to as mixed pallets. As may be realized, such mixedpallets are made of shipping containers (e.g. totes or cases such ascartons, etc.) containing different types of goods. For example, onecase on the mixed pallet may hold grocery products (soup can, soda cans,etc.) and another case on the same pallet may hold cosmetic or householdcleaning or electronic products. Indeed some cases may hold differenttypes of products within a single case. Conventional warehousingsystems, including conventional automated warehousing systems do notlend themselves to efficient generation of mixed goods pallets. Inaddition, storing case units in, for example carriers or on palletsgenerally does not allow for the retrieval of individual case unitswithin those carriers or pallets without transporting the carriers orpallets to a workstation for manual or automated removal of theindividual case units.

It would be advantageous to be able to transport uncontained orunpalletized case units between levels of a storage facility independentof transport device movement between the levels.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the disclosed embodimentsare explained in the following description, taken in connection with theaccompanying drawings, wherein:

FIG. 1 schematically illustrates an exemplary storage and retrievalsystem in accordance with the embodiments;

FIGS. 2A, 2B, 2C, 2D, 3A and 3B illustrate schematic views of a conveyorsystem in accordance with the embodiments;

FIG. 4 illustrates a schematic view of a conveyor shelf in accordancewith the embodiments;

FIG. 5 schematically illustrates a conveyor system in accordance withthe embodiments;

FIGS. 6A-6D schematically illustrate a transfer station in accordancewith the embodiments;

FIG. 7 is a schematic illustration of a method in accordance with theembodiments;

FIG. 8 is a flow diagram of a method in accordance with the embodiments;

FIGS. 9A and 9B illustrate a feed station in accordance with theembodiments;

FIG. 10 illustrates a pickface builder in accordance with theembodiments;

FIG. 11 illustrates a pickface builder in accordance with theembodiments;

FIG. 12 illustrates a pickface builder in accordance with theembodiments;

FIG. 13 illustrates a platform in accordance with the embodiments;

FIG. 14 illustrates platform guides in accordance with the embodiments;and

FIG. 15 illustrates platform guides in accordance with the embodiments.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT(s)

FIG. 1 generally schematically illustrates a storage and retrievalsystem 100 in accordance with the embodiments. Although the disclosedembodiments will be described with reference to the embodiments shown inthe drawings, it should be understood that the disclosed embodiments canbe embodied in many alternate forms. In addition, any suitable size,shape or type of elements or materials could be used.

In accordance with the embodiments the storage and retrieval system 100may operate in a retail distribution center or warehouse to, forexample, fulfill orders received from retail stores for case units(where case units as used herein means items not stored in trays, ontotes or on pallets, e.g. uncontained or items stored in trays, totes oron pallet(s)). It is noted that the case units may include cases ofitems (e.g. case of soup cans, boxes of cereal, etc.) or individualitems that are adapted to be taken off of or placed on a pallet. Inaccordance with the embodiments, shipping cases or case units (e.g.cartons, barrels, boxes, crates, jugs, or any other suitable device forholding items) may have variable sizes and may be used to hold items inshipping and may be configured so they are capable of being palletizedfor shipping. It is noted that when, for example, pallets of itemsarrive at the storage and retrieval system the content of each palletmay be uniform (e.g. each pallet holds a predetermined number of thesame item—one pallet holds soup and another pallet holds cereal) and aspallets leave the storage and retrieval system the pallets may containany suitable number and combination of different items (e.g. each palletmay hold different types of items—a pallet holds a combination of soupand cereal). It is noted that the storage and retrieval system describedherein may be applied to any environment in which items are stored andretrieved.

The storage and retrieval system 100 may be configured for installationin, for example, existing warehouse structures or adapted to newwarehouse structures. In the embodiments, the storage and retrievalsystem 100 may be substantially similar to that described in, forexample, United States Provisional Patent Application “WAREHOUSINGSCALABLE STORAGE STRUCTURE” with Attorney Docket Number 1127P014551-US(-#1) (U.S. Ser. No. 61/423,340) and filed on Dec. 15, 2010 (now U.S.patent application Ser. No. 13/326,674 with Attorney Docket Number1127P014551-US (PAR) filed on Dec. 15, 2011), and U.S. patentapplication Ser. No. 12/757,381, entitled “STORAGE AND RETRIEVALSYSTEM,” filed on Apr. 9, 2010 the disclosures of which are incorporatedherein by reference in their entireties. The storage and retrievalsystem 100 may include in-feed and out-feed transfer devices, such asstations 170, 160, multilevel vertical conveyors 150A, 150B (MVCs), astorage structure 130, and a number of autonomous vehicular transportrobots 110 (referred to herein as “bots”) that may also operate astransfer devices. The storage and retrieval system may also includetransfer devices including robot or bot transfer stations 140 (FIGS.6A-6D) that may provide an interface between the bots 110 and themultilevel vertical conveyors 150A, 150B. It is noted that in theembodiments any suitable transfer device may be provided at any locationand on either side or level of MVC 150A, 150B to remove or pick materialfrom or replace or place material to MVC 150A, 150B at any shelf orplatform level or location or otherwise. The in-feed transfer stations170 and out-feed transfer stations 160 may operate together with theirrespective multilevel vertical conveyors 150A, 150B for transferringitems to and from one or more levels of a multi-level storage structure130. It is noted that while the multilevel vertical conveyors aredescribed herein as being dedicated inbound conveyors 150A and outboundconveyors 150B, each of the conveyors 150A, 150B may be used for bothinbound and outbound transfer of case units/items from the storage andretrieval system. It is noted that while multilevel vertical conveyorsare described herein in other aspects the conveyors may be any suitableconveyors or transfer/picking devices having any suitable transport pathorientation. Bots 110 may be disposed on each level of the multi-levelstorage structure 130 so that the bots 110 on a respective level cantraverse an entirety of that level. The bots 110 may be configured toplace items, such as the above described retail merchandise, intopicking stock as described in U.S. patent application Ser. No.12/757,312, entitled “AUTONOMOUS TRANSPORTS FOR STORAGE AND RETRIEVALSYSTEMS filed on Apr. 9, 2010, the disclosure of which is incorporatedby reference herein in its entirety. Other suitable examples of bots aredescribed in, for example, United States Provisional Patent Applicationentitled “BOT PAYLOAD ALIGNMENT AND SENSING” with Attorney Docket Number1127P014263-US (-#1) (U.S. Ser. No. 61/423,220) and filed on Dec. 15,2010 (now U.S. patent application Ser. No. 13/327,040 with AttorneyDocket Number 1127P014263-US (PAR) filed on Dec. 15, 2011), UnitedStates Provisional Patent Application entitled “AUTOMATED BOT WITHTRANSFER ARM” with Attorney Docket Number 1127P014264-US (-#1) (U.S.Ser. No. 61/423,365) and filed on Dec. 15, 2010 (now U.S. patentapplication Ser. No. 13/326,952 with Attorney Docket Number1127P014264-US (PAR) filed on Dec. 15, 2011), United States ProvisionalPatent Application entitled “BOT HAVING HIGH SPEED STABILITY” withAttorney Docket Number 1127P014266-US (-#1) (U.S. Ser. No. 61/423,359)and filed on Dec. 15, 2010 (now U.S. patent application Ser. No.13/326,447 with Attorney Docket Number 1127P014266-US (PAR) filed onDec. 15, 2011), and United States Provisional Patent Applicationentitled “AUTOMATED BOT TRANSFER ARM DRIVE SYSTEM” with Attorney DocketNumber 1127P014265-US (-#1) (U.S. Ser. No. 61/423,388) and filed on Dec.15, 2010 (now U.S. patent application Ser. No. 13/326,993 with AttorneyDocket Number 1127P014265-US (PAR) filed on Dec. 15, 2011), thedisclosures of which are incorporated by reference herein in theirentireties. In the embodiments, the bots 110 may be configured tointerface directly with the shelves of the multilevel vertical conveyors150A, 150B or the bots 110 may interface indirectly with the multilevelvertical conveyors 150A, 150B through, for example, bot transferstations 140 disposed on a respective level of the multi-level storagestructure 130.

As described above, the storage structure 130 may include multiplelevels of storage rack modules where each level includes respectivepicking aisles 130A and at least one transfer deck 130B for allowing thebots 110 to traverse respective levels of the storage structure 130 fortransferring case units between any of the storage areas of the storagestructure 130 and any shelf of any multilevel vertical conveyor 150A,150B. The picking aisles 130A, and transfer decks 130B also allow thebots 110 to place case units into picking stock and to retrieve orderedcase units. It is noted that each level may also include bot transferstations 140 for allowing the exchange of items between the multilevelvertical conveyors 150A, 150B and a bot on a respective storage level ofthe storage structure 130. The storage structure 130 may besubstantially similar to the storage structure described in UnitedStates Provisional Patent Application “WAREHOUSING SCALABLE STORAGESTRUCTURE” with Attorney Docket Number 1127P014551-US (-#1) (U.S. Ser.No. 61/423,340) and filed on Dec. 15, 2010 (now U.S. patent applicationSer. No. 13/326,674 with Attorney Docket Number 1127P014551-US (PAR)filed on Dec. 15, 2011), and U.S. patent application Ser. No.12/757,381, entitled “STORAGE AND RETRIEVAL SYSTEM,” previouslyincorporated by reference in their entireties.

One or more central system control computers (e.g. control server) 120may coordinate or otherwise control the operation of the multilevelvertical conveyors 150A, 150B with other suitable features of thestorage and retrieval system 100 in a manner substantially similar tothat described in U.S. patent application Ser. No. 12/757,337, entitled“CONTROL SYSTEM FOR STORAGE AND RETRIEVAL SYSTEMS,” and U.S. patentapplication Ser. No. 12/757,220, entitled “STORAGE AND RETRIEVALSYSTEM,” both filed on Apr. 9, 2010, the disclosures of which areincorporated herein by reference in their entireties. For example, thecontrol server 120 may control the operation of the storage andretrieval system 100 through, for example, any suitable communicationsnetwork 180.

The storage structure 130 may be arranged such that if desired there issubstantially no vertical or horizontal array partitioning of thestorage structure. For example, each multilevel vertical conveyor 150A,150B may be common to all or substantially all storage spaces (e.g. thearray of storage spaces) in the storage structure 130 such that any bot110 can access each storage space and any multilevel vertical conveyor150A, 150B can receive case units from any storage space on any level sothat the multiple levels in the array of storage spaces substantiallyact as a single level (e.g. no vertical partitioning). Conversely caseunits from any shelf of each multilevel vertical conveyor 150A, 150B canbe transferred to any or each storage space throughout the storagestructure or to each storage space of any level of the storagestructure. The multilevel vertical conveyors 150A, 150B can also receivecase units from any storage space on any level of the storage structure130 (e.g. no horizontal partitioning). Suitable examples of multilevelvertical conveyors can be found in, for non-limiting exemplary purposes,U.S. patent application Ser. No. 12/757,354, entitled “LIFT INTERFACEFOR STORAGE AND RETRIEVAL SYSTEMS,” and U.S. patent application Ser. No.12/757,220, entitled “STORAGE AND RETRIEVAL SYSTEM,” the disclosures ofwhich are incorporated by reference herein in their entireties.

Referring now to FIG. 2A, the multilevel vertical conveyors will bedescribed in greater detail. It is noted that the input multilevelvertical conveyor 150A and associated in-feed transfer stations 170, aredescribed, however, the out-feed multilevel vertical conveyors 150B, bottransfer stations 140B and out-feed transfer stations 160 may besubstantially similar to that described below for their in-feedcounterparts but for the direction of material flow out of the storageand retrieval system 100 rather than into the storage and retrievalsystem 100. As may be realized, the storage and retrieval system 100 mayinclude multiple in-feed and out-feed multilevel vertical conveyors150A, 150B that are accessible by, for example, bots 110 on each levelof the storage and retrieval system 100 so that one or more caseunit(s), can be transferred from a multilevel vertical conveyor 150A,150B to each storage space on a respective level and from each storagespace to any one of the multilevel vertical conveyors 150A, 150B on arespective level. The bots 110 may be configured to transfer the caseunits (alone or in combinations) between the storage spaces and themultilevel vertical conveyors with one pick (e.g. substantially directlybetween the storage spaces and the multilevel vertical conveyors). Thecase unit(s) being so transferred at one time may be referred togenerally as a pickface. By way of further example, the designated bot110 picks the case unit(s) or pickface from a shelf of a multilevelvertical conveyor, transports the case unit(s) to a predeterminedstorage area of the storage structure 130 and places the case unit(s) orpickface in the predetermined storage area (and vice versa).

Generally, the multilevel vertical conveyors include payload shelves 730(FIGS. 2A-4) attached to chains or belts that form continuously movingor circulating vertical loops (the shape of the loop shown in the Figs.is merely exemplary and in alternate embodiments the loop may have anysuitable shape including rectangular and serpentine) that move at asubstantially constant rate, so that the shelves 730 use what may bereferred to as the “paternoster” principle of continuous conveyance,with loading and unloading performed at any point in the loop withoutslowing or stopping. The multilevel vertical conveyors 150A, 150B may becontrolled by a server, such as for example, control server 120, or anyother suitable controller. One or more suitable computer workstations700 may be connected to the multilevel vertical conveyors 150A, 150B andthe server 120 in any suitable manner (e.g. wired or wirelessconnection) for providing, as an example, inventory management,multilevel vertical conveyor functionality and control, and customerorder fulfillment. As may be realized, the computer workstations 700and/or server 120 may be programmed to control the in-feed and/orout-feed conveyor systems. It is noted that the computer workstations700 and/or server 120 may also be programmed to control the transferstations 140. In the embodiments, one or more of the workstations 700and control server 120 may include a control cabinet, a programmablelogic controller and variable frequency drives for driving themultilevel vertical conveyors 150A, 150B. It should be understood,however, that the workstations 700 and/or control server 120 may haveany suitable components and configuration. The workstations 700 may beconfigured to substantially remedy any exceptions or faults in thein-feed and/or out-feed conveyor systems substantially without operatorassistance and communicate fault recovery scenarios with the controlserver 120 and/or vice versa.

Referring also to FIG. 4, the multilevel vertical conveyors 150A mayinclude a frame 710 configured to support driven members such as, forexample, chains 720. The chains 720 may be coupled to the shelves 730,which are movably mounted to the frame 710 such that the chains 720effect substantially continuous movement of the shelves 730 around theframe 710. However, any suitable drive link, such as for example, beltsor cables may be used to drive the shelves 730. Each shelf 730 mayinclude, for example, supports 930 and a platform 900. The supports 930may extend from the platform 900 and be configured for attaching andmounting the shelf 730 to, for example, one or more drive chains 720.The platform 900 may include, for example, any suitably shaped frame911, which in this example is generally “U” shaped (e.g. having lateralmembers connected by a span member at one end), and a payload orpickface support surface (e.g. in one aspect of the embodiments formedof any suitable number of spaced apart fingers 910 extending from theframe 911). In other aspects, the support surface of the multilevelvertical conveyor may have any suitable configuration, with or withoutspaced fingers or slats. The fingers 910 may be configured forsupporting the pickfaces 750, 752 (FIG. 2B) where each pickfacecomprises at least one uncontained case unit. In the embodiments, eachof the fingers 910 may be removably fastened to a frame 911 forfacilitating replacement or repair of individual fingers 910. Thefingers 910, frame 911 (and supports 930) may form an integral structureor platform that defines the seating surface that contacts and supportsthe uncontained case units. It is noted that the shelf 730 illustratesonly a representative structure and in alternate embodiments, theshelves 730 may have any suitable configuration and size fortransporting pickfaces 750, 752 as will be described further below. Asmaybe realized the fingers 910 of each of the one or more pickfacesupport stations A-D, define the seating surface against which the oneor more uncontained cases of each pickface are gated. As seen in FIG. 5,the pickfaces on the support station may have constraints to preventmovement of the pickface(s) relative to the support stations (A-D). Thespaced apart fingers 910 are configured to interface with, for example,a transfer arm or effector of the bots 110 and the in-feed transferstations 170 for transferring the loads 750, 752 between the multilevelvertical conveyor 150A and one or more of the transfer stations 170 andbots 110. It is noted that the spaced apart fingers 900 may also beconfigured to interface with bot transfer stations 140 as describedbelow.

The multilevel vertical conveyors 150A may also include a suitablestabilizing device(s), such as for example, driven stabilizing chainsfor stabilizing the shelves 730 during vertical travel. In one example,the stabilizing devices may include chain driven dogs that are engagedto the shelves in both the upward and downward directions to form, forexample, a three point engagement with the shelf supports 930. The drivechains 720 for the shelves 730 and stabilizing devices may be drivinglycoupled to for example, any suitable number of drive motors under thecontrol of, for example, one or more of the computer workstations 700and control server 120. Further exemplary embodiments for effectingstability of the conveyor shelves 730 are described later in thespecification.

In the embodiments there may be any suitable number of shelves 730mounted and attached to the drive chains 720. As can be seen in FIG. 2Beach shelf 730 may be configured to carry, for exemplary purposes only,at least two separate pickfaces 750, 752 in corresponding positions A, Con the shelf 730 (e.g. a single vertical conveyor is functionallyequivalent to multiple individually operated conveyors arranged adjacentone another). As can be seen in FIG. 5 the shelves 730′ may beconfigured to carry, for exemplary purposes only, four separatepickfaces 750-753 in corresponding positions A-D. It should beunderstood that each shelf may be configured to carry more or less thanfour separate loads. As described above, each pickface may comprise oneor more uncontained case units and may correspond to the load of asingle bot 110. As may be realized, the space envelope or area platformof each pickface may be different. By way of example, uncontained cases,such as those directly transported by the multilevel vertical conveyorshave various different sizes (e.g. differing dimensions). Also, as notedeach pickface may include one or more uncontained cases. Thus, thelength and width of each pickface carried by the multilevel verticalconveyors may be different. It is noted that each pickface may be brokenbetween, for example, bots 110 where different portions of the pickfaceare transported by more than one bot 110 on, for example, differentlevels of the storage structure 130. As may be realized when a pickfaceis broken each portion of the broken pickface may be considered as a newpickface by the storage and retrieval system 100. For exemplary purposesonly, referring to FIGS. 3A, 3B the shelves 730 of the multilevelvertical conveyors 150A, 150B may be spaced from each other by apredetermined pitch P to allow for placement or removal of loads 810,820 from the substantially continuously moving shelves 730 as will bedescribed below.

Referring now to FIG. 5, and as described above, the multilevel verticalconveyors, such as conveyor 150A are supplied with case units 1000 fromin-feed transfer stations 170 (FIG. 1). As described above, the in-feedtransfer stations 170 may include one or more of depalletizingworkstations, conveyors 240, conveyor interfaces/bot load accumulators1010A, 1010B and conveyor mechanisms 1030. As can be seen in FIG. 5,case units 1000 are moved from, for example depalletizing workstationsby conveyors 240. In this example, each of the positions A-D is suppliedby a respective in-feed transfer station. As may be realized, while thetransfer of case units is being described with respect to shelves 730′it should be understood that transfer of case units to shelves 730occurs in substantially the same manner. For example, position A may besupplied by in-feed transfer station 170A and position C may be suppliedby in-feed transfer station 170B. Referring also to FIG. 2A the in-feedtransfer stations 170A, 170B, for supplying similar sides of the shelf730 (in this example positions A and C, which are disposed side by side,form a first side 1050 of the shelf 730 and positions B and D, which aredisposed side by side, form a second side 1051 of the shelf 730), may belocated one above the other in a horizontally staggered stackedarrangement (an exemplary stacked arrangement is shown in FIG. 2A). Itis noted that the stacked arrangement may be configured so that thein-feed transfer stations are disposed vertically in-line one above theother and extend into the multilevel vertical conveyors by differentamounts for supplying, for example, positions A and B or positions C andD where positions A and B (and positions C and D) are disposed one infront of the other, rather than side by side. It should be understoodthat the in-feed transfer stations may have any suitable configurationand positional arrangement. As can be seen in FIG. 5, the first side1050 and second side 1051 of the shelf 730 are loaded (and unloaded) inopposing directions such that each multilevel vertical conveyor 150A islocated between respective transfer areas 295A, 295B where the firstside 1050 interfaces with a transfer area 295B and the second side 1051interfaces with transfer area 295A.

In the embodiments, the accumulators 1010A, 1010B may be configured toform the case units 1000 into the individual pickfaces 750-753 prior toloading a respective position A-D on the multilevel vertical conveyor730. The computer workstation 700 and/or control server 120 may provideinstructions or suitably control the accumulators 1010A, 1010B (and/orother components of the in-feed transfer stations 170) for accumulatinga predetermined number of items to form the pickfaces 750-753. Theaccumulators 1010A, 1010B may align the case units in any suitablemanner (e.g. making one or more sides of the items flush, etc.) and, forexample, abut the items together. The accumulators 1010A, 1010B may beconfigured to transfer the pickfaces 750-753 to respective conveyormechanisms 1030 for transferring the pickfaces 750-753 to a respectiveshelf position A-D. In the embodiments the conveyor mechanisms 1030 mayinclude belts or other suitable feed devices for moving the pickfaces750-753 onto transfer platforms 1060. The transfer platforms 1060 mayinclude spaced apart fingers for supporting the pickfaces 750-753 wherethe fingers 910 of the shelves 730 are configured to pass between thefingers of the transfer platforms 1060 for lifting (or placing) thepickfaces 750-753 from the transfer platforms 1060. In the embodiments,the fingers of the transfer platforms 1060 may also be movable and serveto insert the pickfaces 750-753 into the path of the shelves 730 in amanner similar to that described below with respect to the bot transferstations 140. It should be understood that the in-feed transfer stations170 (and out-feed transfer stations 160) may be configured in anysuitable manner for transferring case units (e.g. the pickfaces formedby the case units) onto or from respective multilevel vertical conveyors150A, 150B.

It is noted that while the interface between the bot transfer stations140 and the multilevel vertical conveyors 150A, 150B are described itshould be understood that interfacing between the bots 110 and themultilevel vertical conveyors 150A, 150B occurs in a substantiallysimilar manner (e.g. as described in U.S. patent application Ser. No.12/757,312, entitled “AUTONOMOUS TRANSPORTS FOR STORAGE AND RETRIEVALSYSTEMS,” previously incorporated by reference herein in its entirety).For exemplary purposes only, referring now to FIGS. 2B and 6A-6D, themultilevel vertical conveyors 150A transfer pickfaces 750, 752 from, forexample, the in-feed transfer stations 170 (or any other suitable deviceor loading system) to, for example, the bot transfer stations 140associated with each of the levels in the storage structure 130. Inother examples, the pickfaces 750, 752 may be transferred directly fromthe multilevel vertical conveyors 150A to the bots 110 as describedbelow. As may be realized, the bot transfer stations 140 are disposed onrespective levels of the storage structure adjacent the path of travelof the shelves 730 of a respective multilevel vertical conveyor 150A. Inthe embodiments, there may be a bot transfer station 140 correspondingto each of the positions A and C on the shelves 730 (and positions A-Dwith respect to shelf 730′). For example, a first bot transfer station140 may remove load 750 from position A on shelf 730 while another bottransfer station 140 may remove pickface 752 from position C on shelf730 and so on. In the embodiments, one bot transfer station 140 may alsoserve to remove or place case units in more than one position A, C onthe shelves 730. For example, one bot transfer station 140 may beconfigured for removing pickfaces 750, 752 from one or more of positionsA, C of shelf 730. Still, referring also to FIG. 5, one bot transferstation 140 may be configured for removing pickfaces 750, 752 from oneor more of positions A, C on a first side 1050 of the shelf 730′ whileanother bot transfer station 140 may be configured to remove pickfaces751, 753 from one or more positions B, D on a second side 1051 of theshelf 730′. It should be understood that the bot transfer stations 140may have any suitable configuration for accessing any suitable number ofpositions A-D of the shelves 730, 730′.

Each bot transfer station 140 may include a frame 1100, one or moredrive motors 1110 and a carriage system 1130. The frame 1100 may haveany suitable configuration for coupling the bot transfer station 140 to,for example, any suitable supporting feature of the storage structure130, such as a horizontal or vertical support. The carriage system 1130may be movably mounted to the frame 1100 through, for example, rails1120 that are configured to allow the carriage system 1130 to movebetween retracted and extended positions as shown in FIGS. 6A and 6B.The carriage system 1130 may include a carriage base 1132 and fingers1135. The fingers 1135 may be mounted to the carriage base 1132 in aspaced apart arrangement so that the fingers 1135 extend from thecarriage base 1132 in a cantilevered fashion. It is noted that eachfinger 1135 may be removably mounted to the carriage base 1132 forfacilitating replacement or repair of individual fingers 1135. It isnoted that the fingers and carriage base may be of unitary one-piececonstruction. The fingers 1135 of the bot transfer stations 140 may beconfigured to pass between the fingers 910 (FIG. 4) of the shelves 730of the multilevel vertical conveyors 150A (FIG. 1) for removingpickfaces such as pickfaces 1150 (which may be substantially similar topickfaces 750-753) from the shelves 730. The bot transfer station 140may also include a load positioning device 1140 that retractably extendsbetween, for example, the spaced apart fingers 1135 in the direction ofarrow 1181 for effecting positioning of the pickfaces 1150 in apredetermined orientation relative to the bot transfer station 140. Itshould be understood that the carriage system 1130 may have any suitableconfiguration and/or components. The one or more drive motors 1110 maybe any suitable motors mounted to the frame 1100 for causing theextension/retraction of the carriage system 1130 and theextension/retraction of the positioning device 1140 in any suitablemanner such as by, for exemplary purposes only, drive belts or chains.It should be understood that the carriage system and positioning devicemay be extended and retracted in any suitable manner.

In operation, referring also to FIGS. 2C, 2D, 3A and 3B, inboundpickfaces (e.g. pickfaces, which include one or more case units, thatare being transferred into the storage and retrieval system) such aspickface 1150 are loaded on and will circulate around the multilevelvertical conveyor 150A and be removed from a respective conveyor by, forexample, one or more bots 110 for placement in a storage area of thestorage structure (FIG. 8, Blocks 8000 and 8010). As will be describedfurther below, in the embodiments the input loading sequencing of caseunits onto the multilevel vertical conveyors 150A, 150B (e.g. such as atcorresponding feeder input sides of transfer stations 170 and bottransfer locations on respective storage levels) may be substantiallyindependent from the output or unloading sequence of the multilevelvertical conveyors 150A, 150B (e.g. such as at corresponding outputsides of transfer stations 160 and bot transfer locations on respectivestorage levels) and vice versa. In one example, the pickface 1150 may beloaded onto the shelves 730 during an upward travel of the multilevelvertical conveyor 150A and off loaded from the shelves 730 duringdownward travel of the multilevel vertical conveyor 150A. By way ofexample, multilevel vertical conveyor shelves 730 i and 730 ii (FIG. 2D)may be loaded sequentially, but when unloaded, shelf 730 ii may beunloaded before shelf 730 i. It is noted that the shelves 730 may beloaded through one or more cycles of the multilevel vertical conveyor.It should be understood that the pickfaces may be loaded or off loadedfrom the shelves 730 in any suitable manner. As may be realized, theposition of the case units on the multilevel vertical conveyor shelf 730defines the pickface position that the bot 110 picks from. Accordingly,as may be realized, shudder of the pickface conveyor is highlyundesired, especially in that a pickface(s) may remain on the conveyorfor more than one cycle after being loaded. The bot may be configured topick any suitable load or pickface from the shelf 730 regardless of thepickface position on the shelf 730 or the size of the pickface. In theembodiments, the storage and retrieval system 100 may include a botpositioning system for positioning the bot adjacent the shelves 730 forpicking a desired pickface from a predetermined one of the shelves 730(e.g. the bot 110 is positioned so as to be aligned with the pickface).The bot positioning system may also be configured to correlate theextension of a bot transfer arm with the movement (e.g. speed andlocation) of the shelves 730 so that the transfer arm is extended andretracted to remove (or place) pickfaces from predetermined shelves 730of the multilevel vertical conveyors 150A, 150B. For exemplary purposesonly, the bot 110 may be instructed by, for example, the computerworkstation 700 or control server 120 (FIG. 2A) to extend the transferarm into the path of travel of the pickface 1150. As the pickface 1150is carried by the multilevel vertical conveyor 150A in the direction ofarrow 860 fingers of the bot the transfer arm (which may besubstantially similar to fingers 1135 of the bot transfer station 140)pass through the fingers 910 of the shelf 730 for transferring thepickface 1150 from the shelf 730 to the carriage system 1135 (e.g. thepickface 1150 is lifted from the fingers 910 via relative movement ofthe shelf 730 and the bot transfer arm). As may be realized, the pitch Pbetween shelves may be any suitable distance for allowing the transferof pickfaces between the multilevel vertical conveyor and the bots 110while the shelves 730 are circulating around the multilevel verticalconveyor at a substantially continuous rate. The bot transfer arm may beretracted (in a manner substantially similar to that shown in FIGS. 6C,6D with respect to the bot transfer station 140) so that the pickface1150 is no longer located in the path of travel of the shelves 730 ofthe multilevel vertical conveyor 150A. It is noted that where the bottransfer stations 140 are used, the positioning device 1140 may beextended through the fingers 1135 and the carriage system 1130 (FIGS.6A-6D) may be moved in the direction of arrow 1180 for abutting thepickface 1150 against the positioning device 1140 effecting positioningof the pickface 1150 in a predetermined orientation relative to, forexample, the bot transfer station 140. The carriage system 1130 may befully retracted as shown in FIG. 6D for transfer of the pickface 1150 toa bot 110.

Referring to FIGS. 2D and 3B, for transferring loads in the outbounddirection (e.g. moving pickfaces from or out of the storage andretrieval system) the bots 110 pick one or more pickface, such aspickface 1150, from a respective predetermined storage area of thestorage structure (FIG. 8, Block 8020). The pickfaces may be extendedinto the path of the shelves 730 of the multilevel vertical conveyor150B (which is substantially similar to conveyor 150A) by the transferarm of bot 110 through an extension of the bot transfer arm relative toa frame of the bot 110. It is noted that the pickfaces, such as pickface1150, may be placed on the multilevel vertical conveyor 150 in a firstpredetermined order sequence (FIG. 8, Block 8030). The firstpredetermined order may be any suitable order. The substantiallycontinuous rate of movement of the shelves 730 in the direction of arrow870 cause the fingers 910 of the shelf 730 to pass through the fingersof the bot transfer arm such that the movement of the shelf 730 effectslifting the pickface 1150 from the fingers of the bot transfer arm. Thepickface 1150 travels around the multilevel vertical conveyor 150B to anout-feed transfer station 160 (which is substantially similar to in-feedtransfer station 170) where it is removed from the shelf 730 by aconveyor mechanism 1030 in a manner substantially similar to thatdescribed above. The pickfaces may be removed from the multilevelvertical conveyor 150B by, for example the out-feed transfer stations160 in a second predetermined order sequence that may be different andindependent from the first predetermined order sequence (FIG. 8, Block8040). The second predetermined order sequence may depend on anysuitable factors such as, for example, the store plan rules describedbelow. As noted before, to effect transfer of pickface(s) betweenconveyor stations and bot transfer arm or transfer station in a robotrepeatable manner where pickface size and shape may vary with eachtransfer it is desired that the motion of the pickface(s) on theconveyor be substantially free of shudder or judder.

It is noted that the respective transfer of pickfaces between themultilevel vertical conveyors 150A, 150B and the in-feed and out-feedtransfer stations 170, 160 may occur in a manner substantially similarto that described above with respect to the bots 110 and bot transferstations 140. It is noted that transfer of pickfaces between themultilevel vertical conveyors 150A, 150B and the in-feed and out-feedtransfer stations 170, 160 may occur in any suitable manner.

As can be seen in FIGS. 2C and 2D the shelves 730 of the multilevelvertical conveyors 150A, 150B are loaded and unloaded by the in-feed andout-feed transfer stations 170, 160 and the bots 110 from a common sideof the shelf 730. For example, the shelves are loaded and unloaded inthe common direction 999 (e.g. from only one side of the shelf 730). Inthis example, to facilitate loading the multilevel vertical conveyorfrom only one side of the shelf, the multilevel vertical conveyors 150A,150B circumscribe a respective one of the in-feed and out-feed transferstations 170, 160 so that the pickfaces 1150 travel around the in-feedand out-feed transfer stations 170, 160. This allows the in-feed andout-feed transfer stations 170, 160 to be placed on the same side of theshelves 730 as the bots 110 for transferring pickfaces (and the caseunits therein) to and from the multilevel vertical conveyors 150A, 150B.

It is noted that the control server 120 may be configured to order theremoval of case units from the storage and retrieval system for anysuitable purpose, in addition to order fulfillment. In the embodiments,the distribution (e.g. sortation) of case units in the storage andretrieval system is such that the case units in the conveyor can beprovided for delivery to a palletizing station in any suitable order atany desired rate using only two sortation sequences. The control server120 may also be configured to incorporate, for example, store plan ruleswhen fulfilling orders so that the cases are provided by the bots 110 torespective multilevel vertical conveyors 150B in a first predeterminedsequence (e.g. a first sortation of case units) and then removed fromthe respective multilevel vertical conveyors 150B in a secondpredetermined sequence (e.g. a second sortation of case units) so thatthe case units may be placed on pallets or other suitable shippingcontainers/devices) in a predetermined order for building mixed pallets(see e.g. FIG. 8 described above). For example, in the first sortationof case units the bots 110 may pick respective case units (e.g. caseunit) in any order. The bots 110 may traverse the picking aisles andtransfer deck (e.g. circulate around the transfer deck) with the pickeditem until a predetermined time when the item is to be delivered to apredetermined multilevel vertical conveyor 150B. In the second sortationof case units, once the case units are on the multilevel verticalconveyor 150B the case units may circulate around the conveyor until apredetermined time when the items are to be delivered to the out-feedtransfer station 160. Referring to FIG. 7, it is noted that the order ofcase units delivered to the pallets may correspond to, for example,store plan rules 9000. The store plan rules 9000 may incorporate, forexample, an aisle layout in the customer's store or a family group ofcase units corresponding to, for example, a particular location in thestore where the pallet will be unloaded or a type of goods. The order ofcase units delivered to the pallets may also correspond tocharacteristics 9001 of the case units such as, for example,compatibility with other case units, dimensions, weight and a durabilityof the case units. For example, crushable case units may be delivered tothe pallet after heavier more durable case units are delivered to thepallet. The first and second sortations of the case units allow for thebuilding of mixed pallets 9002 as described below.

The control server 120 in combination with the structural/mechanicalarchitecture of the storage and retrieval system enables maximum loadbalancing. As described herein, the storage spaces/storage locations aredecoupled from the transport of the case units through the storage andretrieval system. For example, the storage volume (e.g. the distributionof case units in storage) is independent of and does not affectthroughput of the case units through the storage and retrieval system.The storage array space may be substantially uniformly distributed withrespect to output. The horizontal sortation (at each level) and highspeed bots 110 and the vertical sortation by the multilevel verticalconveyors 150B substantially creates a storage array space that issubstantially uniformly distributed relative to an output location fromthe storage array (e.g. an out-feed transfer station 160 of a multilevelvertical conveyor 150B). The substantially uniformly distributed storagespace array also allows case units to be output at a desiredsubstantially constant rate from each out-feed transfer station 160 suchthat the case units are provided in any desired order. To effect themaximum load balancing, the control architecture of the control server120 may be such that the control server 120 does not relate the storagespaces within the storage structure 130 (e.g. the storage array) to themultilevel vertical conveyors 150B based on a geographical location ofthe storage spaces (which would result in a virtual partitioning of thestorage spaces) relative to the multilevel vertical conveyors 150B (e.g.the closest storage spaces to the multilevel vertical conveyor are notallocated to cases moving from/to that multilevel vertical conveyor).Rather, the control server 120 may map the storage spaces uniformly toeach multilevel vertical conveyor 150B and then select bots 110, storagelocations and output multilevel vertical conveyor 150B shelf placementso that case units from any location in the storage structure come outfrom any desired multilevel vertical conveyor output (e.g. at theout-feed transfer stations) at a predetermined substantially constantrate in a desired order for building the mixed pallets 9002.

Referring now to FIGS. 9A and 9B, there is shown feed station 141 inaccordance with the embodiments. In addition to the features describedbelow, station 141 may be substantially similar to out-feed and in-feedstations 160, 170. Feed station 141 may be an automated device that canbe configured to either transfer payloads referred to as pickfaces,cases or otherwise into an MVC and onto a platform or out of an MVC fromthe platform. It is noted that feed station 141 may be used to transfermaterial to or from any suitable device, station or otherwise. In oneaspect of the disclosed embodiment, feed station 141 may have drivenroller bed 2012 to transfer in the x-axis 2014. Feed station 141 mayhave a set of extendable or retractable fingers and payload bed 2020 (orother suitable effector for picking/placing pickfaces on/off themultilevel vertical conveyor) that traverses in the y-axis 2022 and PLCwith controls 2030. Rollers 2012 may be selectively driven by drivemotor and transmission 2040 where sensors may be provided to detect thepresence, edges or otherwise of the payload to be transported and usedin conjunction with encoders or otherwise with controller 2030 toposition the payload as desired. Gear motor 2050 may be provided toselectively traverse bed 2020 in the y direction 2022. A z axis drive(not shown) may be provided to move bed 2020 in the z direction 2024 toeffect a pick or place to rollers 2012. Feed station's 141 y-axis motionmay be coordinated to transfer loads, for example, payloads, cases orotherwise from or onto the MVC platforms 730, 731 by positioning feedstation fingers 2020 to accept or pass off the payload to or from theplatform 730, 731. Feed station 141 transfers the payload between x andy-axis 2014, 2022 through a z-axis 2024 lift of the fingers 2020. With apickface payload on rollers 2012, once fingers 2020 are lifted, a y-axismove in direction 2022, that may extend fingers 2020, may take place toallow the payload to be transported to the appropriate MVC (in a mannersimilar to that shown in FIG. 5). An opposite sequence may take placewhen transferring a payload from an MVC platform, for example, platform730 or 731 as will be described, to feed station 141 where fingers 2020retract in the y-axis direction 2022 and then lower in the z-axisdirection 2024 to transfer a pickface payload to the roller bed 2012 forremoval. As such, feed station 141 provides for an automated device thatcan be configured to either transfer payloads or cases into an MVC andonto a platform or out of an MVC from the platform. As may be realized,the pickface payload being output by an output MVC from the storage andretrieval system may be different than the input pickface payload. Forexample, as input pickface transported and loaded to a correspondingstorage space in the storage structure and comprising more than onecase(s) may be portioned during retrieval so that no cases of the inputpickface are retrieved, and the retrieved pickface is different than theinput pickface.

Referring now to FIGS. 10, 11 and 12, there is shown pickface builderarrangement 2002 having pickface builder 2010 and feed station 141.Pickface builder 2010, which may hereinafter be referred to as PFB maybe an automated device to align a single or multiple case(s) or pickfaceunits to form the single or multiple case pickface payload for picking,placing or otherwise to be transferred in any suitable direction orotherwise and to be used in conjunction with any suitable conveyance,transport device or otherwise. Although pickface builder 2010 may bedescribed with respect to transfer station 141, pickface builder 2010may be utilized with or without any transfer station, transport systemor otherwise. Further, more or less features may be provided withpickface builder 2010. For example, transport features such asassociated with transfer station 141 or otherwise may be incorporatedinto pickface builder 2010 or more and less sensing, alignment or othersuitable features may be provided. The pickface builder 2002 may belocated in any suitable area of the storage and retrieval system suchas, for example, between the conveyor 240 (see also FIG. 5) and themultilevel vertical conveyor 150. For example, the pickface builder 2010may be arranged downstream from (e.g. adjacent to or offset from) a turnin elbow 240E of the conveyor 240 (e.g. to change a direction of theflow of cases for interfacing with the multilevel vertical conveyor150). It is noted that the conveyor 150 may be configured so that a turnin elbow is not used in which case the pickface builder may interfacewith a substantially straight conveyor. Pickface builder 2010 may havex-y axis pusher 2100 (or a single axis pusher in e.g. the y-axis),y-axis snugger 2120, roller bed 2140 and PLC controls 2160. In oneexample, the x-y axis pusher 2100 may be located to receive cases suchthat the direction of the flow of cases from the conveyor 240 is towardsthe pusher (e.g. the conveyor discharges cases substantially in front ofor adjacent the pusher). In one example, the case configuration uponreceipt by the pusher 2100 may be such that a long axis of the cases isoriented to interface with the pusher 2100. In another example, theshort axis of the cases may be oriented to intake with the pusher 2100(e.g. the cases may have any suitable orientation relative to the pusher2100). It is noted that the cases may have mixed orientations wheninterfacing with the pusher 2100 (e.g. some cases interface the pushervia a long axis of the case and other cases interface with the pushervia the short axis of the case). The x-y axis pusher 2100 directs casesfrom the conveyor 240 towards the snugger 2120. The snugger 2120 may bepositioned substantially opposite the pusher 2100 and substantiallytransverse to the direction of case travel between, for example, feedstation 141 and the multilevel vertical conveyor 150. In one example,the snugger establishes a pickface pick datum. For example, the snugger2120 may push cases up against the snugger 2120 (or vice versa) forsubstantially aligning and snugging the cases (that form a pickface)together. The pickface builder 2010 transfers to and collates thealigned cases (e.g. pickfaces) on the feed station 141 for subsequenttransfer to the multilevel vertical conveyor 150.

Pickface builder pusher 2100 and snugger 2120 have linear actuators2162, 2164, 2166 driven by servo motors. It is noted that any suitableactuator, linear or otherwise may be provided, for example, any suitableother linear motion technologies. In the embodiments, PFB motion istriggered by a sensor 2170 in the pusher 2100, which follows a payloador case throughout travel of pusher 2100 to provide positive presencedetection throughout the x-y motion of pusher 2100. PFB 2010 uses gate2180 to halt x-axis motion of the payload until the full pickface hasbeen built and snugged where the pickface may consist of one or morecases or payloads and where the snugging may consist of positioningcases or payloads adjacent one another or at any suitable location withrespect to the other. Here, pickface builder 2010 pusher 2100 moves inan x-y motion profile that varies depending on payload or casedimensions and the PFB snugger 2120 moves in a y-axis profile which maybe normal to the direction of payload travel or otherwise that variesdepending on an aggregate of all payload or case dimensions in a givenpickface. PFB snugger 2120 may compress all payloads or as is in thepickface in the y-axis to present a compact aggregate of payloads forpicking, placing or subsequent transport. PFB roller bed 2140 may be amotor driven conveyor which provides payload or case motion in thex-axis. It is noted that any suitable form of conveyor such as belt, ora static bed with other means of x-axis conveyance may be provided foruse in conjunction with pusher 2100 and/or snugger 2120. As such,pickface builder 2010 may provide an automated device to align multiplepayloads or cases to present the aggregate for picking, placing orotherwise transferring to or from MVC 150A, B or C or other suitabletransport device. The pickface builder 2010 may be connected to, forexample, any suitable controller such as control server 120 in anysuitable manner. In the embodiments, information from, for example, thecontrol server 120 identifies any suitable ID (identification) data(e.g. SKU numbers, etc.) for each of the incoming cases (e.g. casesbeing placed on and travelling on conveyor 240. For exemplary purposesonly, the ID data may be case specific (such as with the SKU numbers)and may also relate to storage parameters such as for example, a storagelocation within the storage and retrieval system the cases are to bestored and/or particulars for the pickface (e.g. case orientation,contents of a pickface, pickface configuration, etc.). It is noted thatthe case ID data may be any suitable data related to the cases and/orthe storage of the cases within the storage and retrieval system. Thecase ID data (including, but not limited to, SKU numbers, storageparameters, pickface contents, case dimensions etc.) may be storedlocally such as within a memory of the pickface builder 2010 or within amemory of, for example, the control server 120 or any other suitablecontroller. The case ID data may be stored in any suitable format suchas in lookup tables. The controller, such as controller 120 or any othersuitable controller, generates, for example, an x,y movement profile ofthe pusher 2100 and/or a y offset of the snugger 2120 to, for example,establish the datum of the pickface based on any suitable data such asthe case ID data or updated data from any suitable sensors (such asinfeed resolver 2999) placed along the infeed path of the cases (e.g.along conveyor 240 or any other suitable area of the storage andretrieval system).

The in-feed resolver 2999 may be configured to confirm the ID data ofthe incoming cases. The data obtained from, for example, the infeedresolver (such as, for example, the case dimensions and/or any othersuitable case information) may be transmitted in any suitable manner tothe pickface builder 2010 (e.g. directly to the pickface builder orthrough, for example, control server 120) so that the motion profiles ofthe pusher 2100 and snugger 2120 are updated to correspond to anyobserved variances as determined by the infeed resolver 2999.

Referring now to FIG. 13, there is shown exemplary platform 731 of theMVC. In addition to the features described below, platform 731 may havesimilar features as described previously with respect to shelf orplatform 730. Referring also to FIGS. 14 and 15, there is shown MVC 150Chaving platform guides 2200. In addition to the features describedbelow, MVC 150C may have similar features as described with respect toMVC 150A or MVC 150B. In the embodiments platform 731 has guide wheels2210, 2220, 2230 and 2240 mounted to frame 2250. It is noted that anysuitable guide interface (e.g. single or multiple rollers, bearings),may be used in place of wheels. Chain couplers 2260 and 2270 areprovided between rollers 2210, 2230 and frame 2250 respectively. Payloadsupport surfaces 2280 and 2290 are provided coupled to frame 2250.Though the payload support surfaces or stations are shown, the platformmay have more or fewer payload support surfaces or stations in alternateembodiments. MVC 150C has suitable motor drive 2300 which drives chaindrives 2310 and 2320 (through shaft 2330 which in turn drive chainsystems 2330 and 2340 respectively). Platform 731 may be coupled tochain drive 2335 and 2340 with couplings 2270 and 2260 respectively.Although guides 2200 are shown for the upper portion of MVC 150C,similar features may be provided on a lower portion of MVC 150C toprovided continuous guidance of platform 731. Although a single platform731 is shown on MVC 150C, multiple platforms may be provided at a commonor multiple intervals. Guides 2200 are shown having generally four guideportions 2350, 2360, 2370 and 2380 corresponding to guide rollers 2210,2220, 2230 and 2240 respectively and coupled to frame 2205 of MVC 150C.It is noted that the vertical portions of the guides 2350V1, 2350V2,2360V1, 2360V2, 2370V1, 2370V2, 2380V1, 2380V2 are arranged to provide aspace DC between the vertical portions of the guides to allow forpicking and placing case units to the shelves 731 (730′—see FIG. 5) fromboth sides of the shelves. In one aspect, referring also to FIG. 5(which illustrates one side of a multilevel vertical conveyor withtransfer stations 290A, 290B disposed on opposite sides of the shelf730′), one or more transfer areas 295A, 295B may be disposed between thevertical portions of the guides (e.g. within distance DC) fortransferring case units to the shelves 731, 730′ in a mannersubstantially similar to that described above. Guides 2350 and 2370 areprovided offset at a wider stance with respect to guides 2360 and 2380.Guides 2350 and 2370 provide substantially continuous guidance ofrollers 2210 and 2230 throughout the path of travel through MVC 150C andwith breaks at the corners (e.g. the guides are discontinuous) wheresprockets in combination with chain couplings 2260 and 2270 providecontinued guidance of platform 731 and where the breaks prevent an overconstraint. Guides 2360 and 2380 provide substantially continuousguidance of rollers 2220 and 2240 throughout the path of travel throughMVC 150C and with breaks (e.g. the guides are discontinuous) wherecouplings 2260 and 2270 would interfere with guides 2360 and 2380 duringpassage and where guides 2360 and 2380 provide continued guidance ofplatform 731 and where the breaks prevent interference but also whereguide wheel 2220 (see FIG. 13) is actively guided when guide wheel 2240passes a break and where guide wheel 2240 is actively guided when guidewheel 2220 passes a break. As such, a substantially continuous threepoint guidance is accomplished during the entire path of travel. Here,platform 731 travel may be guided by two sets of guide wheels 2210, 2220and 2230, 2240 that travel within channels 2350, 2360 and 2370, 2380 ona predetermined path defined by the channels and drive system. Hence,the guide wheels 2210, 2220, 2230, 2240 and correspondingly the platform(and pickface(s) supported thereby) traveling along the path resistbinding due to a balanced cantilevered arrangement and where transitionsthrough corners are made by substantially continuously having threepoints (wheels) of contact within the roller guides 2350, 2360, 2370,2380, providing smooth (substantially shudder/judder free) transition ofplatform 731 through the entire path of travel within MVC 150C. In theembodiments, one or more MVC(s) 150C enable loading and unloading ofpayloads, cases or pickfaces in storage racks of storage levels.

As noted before, MVC platforms 731 may have more than one pickfacestation, for example, for pickfaces of at least one case(s). Platforms731 are cycled by chain drive 2335, 2340 and use guides 2200 such thatthe stations maintain stability capable of desired positioning ofpickfaces through substantially the full motion cycle within MVC 150Cand without over constraints that may cause shuddering, jamming or otherunsuitable or undesired motions of the pickface(s) to occur. Here, theMVC platform connection to MVC drive system 2260, 2270, and MVC platformguides 2200 are configured to effect three (3) point contact betweenplatform 731 and MVC structure through full motion cycle and withoutover constraints. The platform supports, formed by the guides 220 anddrive system coupling 2260, 2270 form what may be referred to as aguided cantilever restraint that is movable through complete cyclewithout over-constraints, and, as a result without undesirable motion,such as shudder or judder through cycle motion. Accordingly a smooth andeffective load and unload MVC cycle (e.g. infeed to off load for infeedMVC and vice versa for outfeed MVC) as well as MVC sorter (e.g. pickfacepayload moves through more than one cycle) may be provided. In theembodiments, MVC 150C has frame 2205, drive system 2300 and platforms731 that are mounted to the frame and coupled to the drive system 2300so the platforms 731 are cycled vertically in a closed loop. Platform(s)731 may have one or more pickface payload holding stations (in theembodiment shown, two 2280, 2290) that are located offset from eachother, for example, positionally distributed on platform. It should beunderstood that more or less locations may be provided. Each holdingstation may be configured for holding pickface of (one or more)uncontained cases(s). Each holding station may independently fed andoffloaded. Independent feeds may have pickface builders which may beaccommodated by MVC structure and motion path profile(s). Further, MVC150C may be both a multilevel loader/unloader and sorter. In theembodiments, frame 2205 and drive 2300 may be configured to effectplatform 731 motion that results in a vertical or horizontal cyclecomponent in a same direction as load/unload transfer axis for a givenpickface, for example, front-back. The interface may be to warehouseconveyors, for example, a load station for infeed to MVC 150C or anunload station for outfeed from MVC 150C as may be located interior toframe 2205 and transport loop path of platforms 731 of MVC 150C.Interface with rack storage and retrieval system, for example, bot toMVC transfer locations may be provided on an outside of the transportloop path of platforms 731 of MVC 150C. It should be understood that anysuitable in feed or out feed may be provided on the inside, outside orotherwise of the transport path of platforms 731 of MVC 150C. In a firstaspect of the embodiments, a multilevel vertical conveyor system fortransporting uncontained case units to and from a multilevel storagestructure having an array of vertically stacked storage levels isprovided. The multilevel vertical conveyor includes a frame havingdiscontinuous platform guide members, a drive member connected to theframe, and support platforms coupled to the drive member, each of thesupport platforms having support members and at least two followermembers configured to engage the discontinuous platform guide members.The drive member is configured to move the support platforms relative tothe frame in a substantially continuous vertical loop, each of thesupport platforms being configured to support multiple uncontained caseunits where each of the multiple uncontained case units is disposed at arespective predetermined area of a respective support shelf. The supportmembers are guided by the discontinuous platform guide memberssubstantially throughout a path of the substantially continuous verticalloop, where the support members are guided in three point contactsubstantially throughout the path through engagement of the at least twofollower members with the discontinuous platform guide members where thethree point contact is effected by one of the at least two followermembers engaging a respective discontinuous platform guide member whenanother of the at least two follower members passes a discontinuity inthe respective guide member.

In accordance with the first aspect of the embodiments, the multipleuncontained case units are cantilevered on the support platforms.

In accordance with the first aspect of the embodiments, the respectivepredetermined area of the respective support platform comprises an arrayof predetermined areas.

In accordance with the first aspect of the embodiments, the supportmembers are guided in three point contact by the guide memberssubstantially throughout the path.

In accordance with a first sub-aspect of the first aspect of theembodiments, at least one transfer device extends into a path of thesupport platforms, the at least one transfer device being configured toload or unload the uncontained case units from a respectivepredetermined area of a support platform.

In accordance with the first sub-aspect of the first aspect of theembodiments, at least one of the uncontained case units are placed in orremoved from the respective predetermined area of the respective supportplatform substantially independent of other uncontained case unitsdisposed in another different respective predetermined area of therespective support platform.

In accordance with the first sub-aspect of the first aspect of theembodiments, the at least one transfer device comprises at least onein-feed transfer station extending into a path of the support platforms,the support platforms being configured to interface with the at leastone in-feed transfer station to receive the uncontained case units, fromthe at least one in-feed transfer station, in at least one predeterminedarea of an inbound support platform, the at least one predetermined areaof the inbound support platform corresponding to a location of the atleast one in-feed transfer station. In a further aspect the at least onein-feed transfer station comprises an accumulator configured to formindividual bot loads or uncontained case units for placement into therespective predetermined area of the inbound support platform, where theuncontained case units include at least one uncontained case unit. Inanother aspect the at least one in-feed transfer station comprises adepalletizer for removing the uncontained case units from a container.

In accordance with the first sub-aspect of the first aspect of theembodiments, the at least one transfer device comprises at least oneout-feed transfer station extending into the path of the supportplatforms, the support shelves being configured to interface with the atleast one out-feed transfer station to remove the uncontained caseunits, with the at least one out-feed transfer station, from at leastone predetermined area of an outbound support platform, thepredetermined area of the outbound support platform corresponding to alocation of the at least one out-feed transfer station. In a furtheraspect the at least one out-feed transfer station comprises a palletizerfor placing the uncontained case units to a container. In yet anotheraspect the support platforms and the at least one out-feed transferstation are configured such that uncontained case units are removed fromthe support platforms in a predetermined order.

In accordance with the first sub-aspect of the first aspect of theembodiments, each support platform comprises first elongated fingers andthe at least one transfer device comprises second elongated fingers, thefirst and second elongated fingers being configured to allow the supportplatforms to pass through the at least one transfer device for effectinga transfer of the multiple uncontained case units.

In accordance with the first sub-aspect of the first aspect of theembodiments, wherein the at least one transfer device comprises morethan one transfer device disposed in a horizontally staggered verticalstack on respective inbound and outbound sides of the vertical conveyorsystem.

In accordance with the first sub-aspect of the first aspect of theembodiments, wherein the at least one transfer device comprises morethan one transfer device disposed in vertical stacks one above the otheron respective inbound and outbound sides of the vertical conveyor systemsuch that at least one of the more than one transfer device extends intorespective inbound and outbound support platforms by different amountsthan other ones of the at least one transfer device.

In accordance with the first sub-aspect of the first aspect of theembodiments, the at least one transfer device comprises bot transferlocations disposed on each level of the multilevel storage structure forallowing transport vehicles to transfer the uncontained case unitsbetween storage modules disposed on each level and the supportplatforms.

In accordance with the first aspect of the embodiments, the multilevelvertical conveyor system further comprises transport vehicles configuredto interface directly with the support platforms, each of the transportvehicles being configured to transport at least one uncontained caseunit between the support platforms and storage modules of a respectivestorage level with substantially one picking operation.

In a second aspect of the embodiments, a transport system for a storageand retrieval system having an array of storage levels where eachstorage level having respective storage areas is provided. The transportsystem has a vertical conveyor having a frame with discontinuousplatform guide members and support platforms movably coupled to theframe, the support platforms having at least two follower membersconfigured to engage the discontinuous platform guide members and beingconnected to the frame through a three point of contact connectioneffected by one of the at least two follower members engaging arespective discontinuous platform guide member when another of the atleast two follower members passes a discontinuity in the respectiveguide member. The transport system also includes a transfer devicelocated on respective ones of the storage levels. Each support platformis configured to hold one or more uncontained case units inpredetermined areas of the support platform. The vertical conveyor isconfigured to transport the one or more uncontained cases to or frommore than one of the storage levels where the one or more uncontainedcases may be selectably placed on or removed from the vertical conveyorby the transfer device, the vertical conveyor having a conveyor totransfer device interface configured to transfer the uncontained caseunits substantially directly between each support platform and thetransfer device for transport to or from the storage areas.

In accordance with the second aspect of the embodiments, thepredetermined areas comprise an array of areas, and the one moreuncontained cases may be selectably placed on or removed from a platformwith more than one transfer device interfacing to different portions ofthe predetermined areas.

In accordance with the second aspect of the embodiments, the supportplatforms include first elongated fingers and the transfer deviceincludes second elongated fingers, the first and second elongatedfingers being configured to pass between one another for transferringuncontained case units between each support platform and the transferdevice.

It should be understood that the embodiments described herein may beused individually or in any suitable combination thereof. It should alsobe understood that the foregoing description is only illustrative of theembodiments. Various alternatives and modifications can be devised bythose skilled in the art without departing from the embodiments.Accordingly, the present embodiments are intended to embrace all suchalternatives, modifications and variances that fall within the scope ofthe appended claims.

What is claimed is:
 1. A method for transporting uncontained case unitsto and from a multilevel storage structure having an array of verticallystacked storage levels, the method comprises: providing a frame havingdiscontinuous platform guide members; providing a drive member connectedto the frame; and providing support platforms coupled to the drivemember, each of the support platforms having at least two followermembers that engage the discontinuous platform guide members; and movingthe support platforms with the drive member relative to the frame alonga continuous vertical loop transport path, where the support members areguided by the discontinuous platform guide members in three pointcontact substantially throughout the continuous vertical loop transportpath through engagement of the at least two follower members with thediscontinuous platform guide members where three point contact iseffected by one of the at least two follower members engaging arespective discontinuous platform guide member when another of the atleast two follower members passes a discontinuity in the respectiveguide member.
 2. The method of claim 1, further comprising supportingmultiple uncontained case units with the support platforms where themultiple uncontained case units are cantilevered on the supportplatforms.
 3. The method of claim 1, further comprising disposingmultiple uncontained case units in an array of predetermined areas ofthe support platform.
 4. The method of claim 1, further comprisingproviding at least one transfer device that extends into the continuousvertical loop transport path, where the at least one transfer deviceloads or unloads uncontained case units from a respective predeterminedarea of a support platform.
 5. The method of claim 4, wherein at leastone of the uncontained case units are placed in or removed from therespective predetermined area of a respective support platformsubstantially independent of other uncontained case units disposed inanother different respective predetermined area of the respectivesupport platform.
 6. method of claim 4, wherein the at least onetransfer device includes at least one in-feed transfer station thatextends into the continuous vertical loop transport path, where thesupport platforms interface with the at least one in-feed transferstation to receive the uncontained case units, from the at least onein-feed transfer station, in at least one predetermined area of aninbound support platform, the at least one predetermined area of theinbound support platform corresponding to a location of the at least onein-feed transfer station.
 7. The method of claim 4, wherein the at leastone transfer device includes at least one out-feed transfer station thatextends into the continuous vertical loop transport path, where thesupport platforms interface with the at least one out-feed transferstation to remove the uncontained case units, with the at least oneout-feed transfer station, from at least one predetermined area of anoutbound support platform, the predetermined area of the outboundsupport platform corresponding to a location of the at least oneout-feed transfer station.
 8. The method of claim 4, wherein eachsupport platform includes first elongated fingers and the at least onetransfer device includes second elongated fingers, where the first andsecond elongated fingers allow the support platforms to pass through theeach of the at least one transfer device for effecting a transfer of themultiple uncontained case units.
 9. The method of claim 4, wherein theat least one transfer device includes more than one transfer devicedisposed in a horizontally staggered vertical stack on respectiveinbound and outbound sides of the continuous vertical loop transportpath.
 10. The method of claim 4, wherein the at least one transferdevice includes more than one transfer device disposed in verticalstacks one above the other on respective inbound and outbound sides ofthe continuous vertical loop transport path such that the at least oneof the more than one transfer device extends into respective inbound andoutbound support platforms by different amounts than other ones of theat least one transfer device.
 11. A method for transporting uncontainedcase units to and from a multilevel storage structure having an array ofvertically stacked storage levels, the method comprises: providing aframe having discontinuous platform guide members; providing a drivemember connected to the frame; and providing support platforms coupledto the drive member, each of the support platforms having at least twofollower members that engage the discontinuous platform guide members;moving the support platforms with the drive member relative to the framealong a continuous vertical loop transport path, where the supportmembers are guided by the discontinuous platform guide members in threepoint contact substantially throughout the continuous vertical looptransport path through engagement of the at least two follower memberswith the discontinuous platform guide members where three point contactis effected by one of the at least two follower members engaging arespective discontinuous platform guide member when another of the atleast two follower members passes a discontinuity in the respectiveguide member; and transferring one or more uncontained case unitsbetween a transfer device located on respective ones of the storagelevels and the support platforms.
 12. The method of claim 11, furthercomprising selectably placing or removing the one or more uncontainedcase units to or from the support platforms with the transfer devicethrough a transfer device interface that provides a substantially directtransfer between each support platform and the transfer device.
 13. Themethod of claim 12, wherein each support platform includes an array ofpredetermined areas, and the one or more uncontained case units areselectably placed on or removed from a support platform with more thanone transfer device interfacing to different portions of the array ofpredetermined areas.
 14. The method of claim 11, wherein transferringone or more uncontained case units between the transfer device and thesupport platforms includes passing first elongated fingers of thesupport platforms between second elongated fingers of the transferdevice.
 15. The method of claim 11, wherein transferring the one or moreuncontained case units between the transfer device and the supportplatforms includes transferring the one or more uncontained case unitsto and from autonomous transport vehicles disposed on the respectiveones of the storage levels.
 16. The method of claim 15, wherein theautonomous transport vehicles interface substantially directly with thesupport platforms such that each autonomous transport vehiclestransports at least one uncontained case unit between the supportplatforms and storage modules of the respective storage level withsubstantially one picking operation.
 17. The method of claim 11, whereinthe transfer device includes more than one transfer device disposed in ahorizontally staggered vertical stack on respective inbound and outboundsides of the continuous vertical loop transport path.
 18. The method ofclaim 11, wherein the transfer device includes more than one transferdevice disposed in vertical stacks one above the other on respectiveinbound and outbound sides of the continuous vertical loop transportpath such that at least one of the more than one transfer device extendsinto respective inbound and outbound support platforms by differentamounts than other ones of the more than one transfer device.
 19. Amethod for transporting uncontained case units to and from a multilevelstorage structure having an array of vertically stacked storage levels,the method comprises: providing a frame having discontinuous platformguide members; providing a drive member connected to the frame; andproviding support platforms coupled to the drive member, each of thesupport platforms having at least two follower members that engage thediscontinuous platform guide members; moving the support platforms withthe drive member relative to the frame along a continuous vertical looptransport path, where the support members are guided by thediscontinuous platform guide members in three point contactsubstantially throughout the continuous vertical loop transport paththrough engagement of the at least two follower members with thediscontinuous platform guide members where three point contact iseffected by one of the at least two follower members engaging arespective discontinuous platform guide member when another of the atleast two follower members passes a discontinuity in the respectiveguide member; and holding one or more uncontained case units inpredetermined areas of the support platforms substantially throughoutthe continuous vertical loop transport path and transporting the one ormore uncontained case units to or from more than one of the verticallystacked storage levels, where the one or more uncontained case units aresubstantially directly placed on or removed from the predetermined areasof the support platforms by a transfer device disposed on a respectivestorage level.
 20. The method of claim 19, wherein the predeterminedareas include an array of areas, and the one or more uncontained caseunits are selectably placed on or removed from a support platform withmore than one transfer device interfacing to different portions of thepredetermined areas.